Workpiece guard and blade guard for band saw

ABSTRACT

A hand-held band saw for cutting a workpiece. The hand-held band saw includes a deck, first and second wheels coupled to the deck for receiving a continuous blade thereabout, a motor coupled to the deck for driving at least one of the first or second wheels, and a handle providing a grip for a user to hold the band saw. The band saw also includes a blade guard having a first portion adjacent the first wheel, a second portion adjacent the second wheel, and a third portion adjoining the first and second portions. A joint couples the first, second, and third portions to the deck for simultaneous movement of the first, second, and third portions with respect to the deck.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.14/193,457 filed Feb. 28, 2014, which is a divisional of U.S. patentapplication Ser. No. 13/153,090 filed Jun. 3, 2011, now U.S. Pat. No.8,677,633, which claims priority to U.S. Provisional Patent ApplicationNo. 61/351,118 filed Jun. 3, 2010. The entire contents of all theseapplications are incorporated herein by reference.

BACKGROUND

The present invention relates to power tools, and more particularly toband saws.

Band saws typically include a continuous band saw blade disposed about apair of pulleys, or wheels, and driven by one of the pulleys, and aguard surrounding an outer circumference of the band saw blade. Theguard covers the side of the band saw blade as it rotates about thewheels and protects the band saw blade from being disrupted and/ormisaligned. The bottom of the band saw is open such that the band sawblade and pulleys are accessible for removal to facilitate band sawblade replacement.

SUMMARY OF THE INVENTION

The invention provides, in one aspect, a method of manufacturing a bandsaw. The method includes providing a deck, coupling first and secondwheels to the deck for receiving a continuous blade thereabout, couplinga motor to the deck for driving at least one of the first or secondwheels, providing a handle for a user to hold the band saw, providing ablade guard having a first portion adjacent the first wheel and a secondportion adjacent the second wheel, fixing the first and second portionsto each other, and hingedly coupling the first and second portions tothe deck for simultaneous movement with respect to the deck.

In another aspect, the invention provides a hand-held band saw forcutting a workpiece. The hand-held band saw includes a deck, first andsecond wheels coupled to the deck for receiving a continuous bladethereabout, a motor coupled to the deck for driving at least one of thefirst or second wheels, and a handle providing a grip for a user to holdthe band saw. The band saw also includes a blade guard having a firstportion adjacent the first wheel, a second portion adjacent the secondwheel, and a third portion adjoining the first and second portions. Ajoint couples the first, second, and third portions to the deck forsimultaneous movement of the first, second, and third portions withrespect to the deck.

In yet another aspect, the invention provides a hand-held band saw forcutting a workpiece. The hand-held band saw includes a deck defining afront and a rear, the deck having an opening in the front defining a cutzone and a first deck portion generally located on a first side of theopening and a second deck portion generally located on a second side ofthe opening. The band saw also includes a first wheel supported by thefirst deck portion, a second wheel supported by the second deck portion,the first and second wheels for supporting a blade. The band saw alsoincludes a motor operably coupled to the first wheel, a handle providinga grip for a user to hold the band saw, a blade guard configured toprovide a barrier between the blade and an exterior of the band saw, anda joint between the blade guard and the deck such that the blade guardis movable with respect to the deck. The blade guard includes a firstportion adjacent the first wheel, a second portion adjacent the secondwheel, and a third portion adjoining the first and second portions suchthat the first, second, and third portions move as one piece withrespect to the deck.

Other features and aspects of the invention will become apparent byconsideration of the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a band saw according to oneconstruction of the invention.

FIG. 2 is a front view of the band saw shown in FIG. 1.

FIG. 3 is a top view of the band saw shown in FIG. 1.

FIG. 4 is a left side view of a band saw shown in FIG. 1.

FIG. 5 is a bottom perspective view of a portion of the band saw shownin FIG. 1.

FIG. 6 is a cross section of a portion of the band saw of FIG. 3 takenalong line 6-6.

FIG. 7 is a bottom perspective view of the band saw of FIG. 1 shown inan open position.

FIG. 8 is a rear view of the band saw shown in FIG. 1.

FIG. 9 is an exploded view of a portion of the band saw shown in FIG. 1.

FIG. 10 is an exploded view of a portion of the band saw shown in FIG.1.

FIG. 11 is an exploded view of a portion of the band saw shown in FIG.1.

FIG. 12 is a bottom view of the band saw shown in FIG. 1.

FIG. 13 is an exploded view of the band saw shown in FIG. 1.

FIG. 14 is a cross section of the band saw of FIG. 3 taken along line14-14.

FIG. 15 is an enlarged view of a portion of the cross section of FIG.14.

FIG. 16 is a perspective view of a tensioning mechanism of the band sawshown in FIG. 1.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1-16 illustrate a band saw 10 having a frame or housing 12according to one construction of the invention. The housing 12 includesa deck 14 supporting a motor 16 (FIG. 14) and a gear box 18 and a bladeguard 20 coupled to the deck 14. In the illustrated construction, themotor 16 is configured as a DC motor, and the band saw 10 includesremovable, rechargeable battery 22 to deliver power to the motor 16. Themotor 16 is enclosed by a housing 17, preferably formed of plastic. Thegear box 18 is preferably formed of a metal. Other suitable materialsmay be employed.

The motor 16 is drivingly connected to a drive assembly 24 (FIG. 14) atleast partially housed within the gear box 18. The drive assembly 24 mayinclude any of a number of different gear train arrangements configuredto provide a low-speed, high-torque output from the high-speed,low-torque input provided by the motor 16. The motor 16 and the driveassembly 24 are operable to drive a continuous band saw blade 26 havinga cutting edge 114 to cut a workpiece 28.

With particular reference to FIGS. 1-3, the housing 12 includes a singlehandle 30 supporting a trigger switch 32 to provide power to the bandsaw 10. The switch 32 is operable to control operation of the motor 16.Generally, the handle 30 is shaped and arranged for one-handed operationof the band saw 10 as the workpiece 28 is cut. The handle 30 includes agrip portion 34 adjacent the trigger 32. The grip portion 34 is shapedfor accommodating a gripping action by the user's hand during operationof the band saw 10.

In the illustrated construction, the battery 22 is a 12-volt power toolbattery coupled to the handle 30. The battery 22 is coupled to a portionof the handle 30 adjacent the grip portion 34. The battery 22 is coupledto the handle 30 by inserting a portion of the battery 22 within aportion of the handle 30, i.e., a cavity or recess 36 formed in thehandle 30 for receiving the battery 22. In further constructions, thebattery 22 may be coupled to the handle 30 by sliding, snapping,rotating, or the like. The recess 36 also includes a terminal assembly(not shown) for electrically connecting the battery 22 to the band sawmotor 16 via an electrical circuit (not shown). The battery 22 includesLithium-ion battery cells. In other constructions of the band saw 10,the battery 22 may have higher or lower nominal voltage. Additionally oralternatively, the battery cells may have chemistries other thanLithium-ion such as, for example, Nickel Cadmium, Nickel Metal-Hydride,or the like. In other constructions, other sources of power, such as apower cord to provide AC power to an AC motor, may be employed.

With particular reference to FIG. 3, the housing 12, and moreparticularly the deck 14 and the guard 20, defines an opening orU-shaped cavity 38. A first housing portion 40 is generally defined toone side of the opening 38 and a second housing portion 42 is generallydefined to the opposite side of the opening 38. The opening 38 receivesthe workpiece 28 and includes a cut zone 44 in which the workpiece 28 iscut by a portion of the band saw blade 26 that is located in the opening38. With particular reference to FIG. 1, the opening 38 is delimited byfirst and second parallel, facing planes 46, 48 that are substantiallynormal to the portion of the band saw blade 26 positioned in the opening38. The portion of the saw blade 26 positioned in the opening 38 definesa cutting axis C intersecting each of the planes 46, 48 and is orientedsubstantially normal to each of the planes 46, 48 between the respectiveplanes 46, 48. The opening 38 has a width W1 defined as theperpendicular distance between the first and second planes 46, 48.

The handle 30 extends from a top of the deck 14 on a side of the deckopposite the cutting edge 114 of the blade 26, and extends from thefirst housing portion 40 on one end and the second housing portion 42 onthe other end. Thus, the handle 30 extends between the first housingportion 40 and the second housing portion 42. The handle 30 ispositioned at the rear of the band saw 10 opposite the cut zone 44. Thegrip portion 34 is positioned substantially between the first and secondplanes 46, 48. The grip portion 34 is adjacent the trigger 32 andconfigured to be grasped by an operator's hand. The trigger 32 is alsoat least partially positioned between the first and second planes 46,48. In other constructions, the trigger 32 may be positioned outside ofthe first and second planes 46, 48 and adjacent or near one of the firstand second planes 46, 48.

Referring to FIG. 5, the band saw 10 includes a first guide roller set50 disposed on one side of the cavity 38 adjacent the first plane 46 andon the first housing portion 40, and a second guide roller set 52disposed on an opposite side of the cavity 38 adjacent the second plane62 and on the second housing portion 42. Each of the guide roller sets50, 52 includes a pair of aligned rollers 54, 56, respectively, withwhich opposite sides of the saw blade 26 are engaged and a respectivemounting block 58, 60 to which the rollers 54, 56 are rotatablysupported. The mounting blocks 58, 60 are coupled to the deck 14 (e.g.,using fasteners). The first and second guide roller sets 50, 52 supportthe band saw blade 26 as the blade 26 enters and exits the cut zone 44.

With reference to FIG. 7, the band saw 10 includes a drive wheel 62 anda driven wheel 64. The drive wheel 62 is generally disposed in the firsthousing portion 40 and the driven wheel 64 is generally disposed in thesecond housing portion 42. The drive wheel 62 rotates about a drivewheel axis 66 defined by a drive wheel axle 68 and is drivinglyconnected to the motor 16 via the drive assembly 24 in the gear box 18.The driven wheel 64 rotates about a driven wheel axis 70 defined by adriven wheel axle 72 and is rotatably supported by the deck 14. Adistance D (FIG. 1) between the driven wheel axis 70 and the drive wheelaxis 66 is approximately 6.75 inches, and the drive and driven wheels62, 64 each have a diameter of approximately 3.5 inches. In otherconstructions, the band saw 10 may be smaller or larger.

A drive tire 74 and a driven tire 76 are coupled to the periphery of therespective drive wheel 62 and the driven wheel 64. Each of the tires 74,76 is a circular-shaped ring formed of a soft and/or flexibleelastomeric material that is able to lock or adhere to the drive wheel62 or the driven wheel 64. The band saw blade 26 extends around thedrive wheel 62 and the driven wheel 64 and grips the tires 74, 76 and,as a result, motion from the drive wheel 62 is transmitted to the bandsaw blade 26 via the wheel tires 74, 76.

With reference to FIGS. 1 and 13-16, the band saw 10 also includes ablade tensioning mechanism 78 coupled to the deck 14 to adjustablyprovide appropriate tension on the band saw blade 26. The bladetensioning mechanism 78 is operable to move the driven wheel axle 72closer to or farther away from the drive wheel axle 68 in order todecrease or increase the tension in the band saw blade 26, respectively.Specifically, the blade tensioning mechanism 78 includes a lever 80having a pivot axis 82 and an eccentric lobe 84 coupled to the lever 80and defining a central axis 86 that is parallel to and non-coincidentwith the pivot axis 82.

The blade tensioning mechanism 78 also includes a spring guide 88,preferably formed by stamping, having guide pins 90 formed as one piecetherewith. The tensioning mechanism 78 also includes springs 92, such ascoil springs, each of which is disposed about one of the guide pins 90,and a lobe guide 94 for receiving the eccentric lobe 84. The lobe guide94 is coupled to and positioned in sliding relationship with the guidepins 90 and is limited, or stopped, at one end of the guide pins 90 bystops 96. One free end of each spring 92 abuts the spring guide 88 andanother free end of each spring 92 abuts the lobe guide 94.

The driven wheel axle 72 is fastened to the spring guide 88 by way of athreaded fastener 98 and tilting blocks 100, 102. The tilting blocks100, 102 include angled seats 101, 103 (FIG. 15), respectively, forreceiving the threaded fastener 98 at a slight angle with respect to thedrive wheel axis 66 for tiling the driven wheel axle 72 at the slightangle. For example, the driven wheel axle 72, and therefore the drivenwheel axis 70, is tilted at an angle of about 1 to 3 degrees withrespect to the drive wheel axis 66, and preferably about 1.25 degrees.The tiling of the driven wheel 64 provides an improved grip between theband saw blade 26 and the tire 76.

When the lever 80 is rotated such that the eccentric lobe 84 moves in anarcuate path in a direction towards the drive wheel 62, the eccentriclobe 84 pulls the lobe guide 94 towards the drive wheel 62. The lobeguide 94 thereby abuts the stops 96 and pulls the spring guide 88towards the drive wheel 62, which pulls the driven wheel 64 towards thedrive wheel 62, thus creating slack in the blade 26. Conversely, whenthe lever 80 is rotated such that the eccentric lobe 84 moves in anarcuate path in a direction away from the drive wheel 62, the eccentriclobe 84 pushes the lobe guide 94 towards the springs 92. The lobe guide94 moves against the bias of the springs 92, which in turn pushes thedriven wheel 64 away from the drive wheel 62, thereby creating tensionin the blade 26.

With reference to FIGS. 1-4, the band saw 10 includes a bridge 104, orworkpiece guard, for limiting the range of movement of the workpiece 28after a cutting operation. The bridge 104 includes a U-shaped memberextending from the housing 12, and specifically from the deck 14, in adirection away from the blade 26, or away from the opening 38. TheU-shaped member includes first and second portions 106, 108 extendingfrom the deck 14 and a third portion 110 extending between the first andsecond portions 106, 108. The first portion 106 extends from the deck 14on the first housing portion 40 in a direction substantiallyperpendicular to the cutting axis C. The second portion 108 extends fromthe deck 14 on the second housing portion 42 in a directionsubstantially perpendicular to the cutting axis C. The third portion 110extends between the first and second portions 106, 108 in a directionsubstantially perpendicular to the first and second portions 106, 108.In other constructions, one of the first and second portions 106, 108may be absent such that the third portion 110 is cantilevered from theother of the first and second portions 106, 108.

As is best illustrated in FIG. 2, the third portion 110 of the bridge104 is disposed between an upper surface 112 of the deck 14, i.e., thesurface facing the handle 30, and the handle 30. The third portion 110is positioned at a perpendicular distance from the cutting edge 114(FIG. 2) of the blade 26 at least equal to a width W2 of the cut zone44. The width W2 of the cut zone is defined as the perpendiculardistance between a support surface 118 of a shoe 116 (which will bedescribed in greater detail below) and the second plane 48. As such, theworkpiece 28 is provided with enough space for the cutting operation tobe completed without the bridge 104 limiting the cut. In a preferredconstruction, the width W2 is between approximately 1.5 and 1.8 inches,and is preferably approximately 1.65 inches.

The bridge 104 spans the opening 38 between the first housing portion 40and the second housing portion 42, or, in other words, between the firstand second planes 46, 48. As best shown in FIG. 5, the bridge 104 isintegrated, or formed as one piece, with the mounting blocks 58, 60 towhich the guide roller sets 50, 52 are attached. This structure providesrigidity to the band saw 10 between the first housing portion 40 and thesecond housing portion 42. In other constructions, the bridge 104 may beformed as a separate piece from the mounting blocks 58, 60 and may becoupled to the mounting blocks 58, 60 or coupled directly to the deck14. As best shown in FIG. 4, the bridge 104 is angled with respect tothe drive wheel axis 66 at an angle similar to an angle of the blade 26in the cut zone 44 and to an angle A of the handle 30 with respect tothe drive wheel axis 66. In one construction, the angle A is betweenapproximately 20 and 35 degrees and is preferably approximately 27degrees. Other suitable angles may be employed.

The band saw 10 also includes a shoe 116 having a support surface 118against which the workpiece 28 is abutted during a cutting operation.Best illustrated in FIG. 10, the shoe 116 is fastened to the band saw 10by way of threaded fasteners 120, such as screws. The bridge 104includes a shoe-receiving boss 122 to which the shoe 116 is fastened bythe screws 120. The shoe-receiving boss 122 includes three apertures 123for receiving the screws 120, and the shoe 116 includes two apertures125 for receiving the screws 120, such that the shoe 116 is securable intwo different positions with respect to the bridge 104.

With particular reference to FIGS. 7-9 and 12-13, the housing 12includes the blade guard 20 pivotally coupled to the deck 14 for pivotalmovement between a closed position (FIG. 1) and an open position (FIG.7). In the illustrated construction, the blade guard 20 is formed as aseparate piece from the deck 14 and is coupled to the deck 14 by way ofa hinge 124 for pivotal movement relative to the deck 14. The hinge 124,such as a barrel hinge, includes barrel sections 126, 128 formedalternatingly with the deck 14 and the blade guard 20, respectively, anda pin 130 (FIG. 4) passing through the barrel sections 126, 128 andproviding a pivot axis 132. In the illustrated construction, the pin 130is formed from metal, the deck 14 and barrel sections 126 are formed asone piece from a polymer, and the blade guard 20 and barrel sections 128are formed as one piece from a polymer. In other constructions, othersuitable materials may be employed.

In the closed position, the deck 14 and the blade guard 20 cooperate tosubstantially enclose the band saw blade 26, except the portion of theband saw blade 26 positioned in the cut zone 44 (i.e., the portion ofthe band saw blade 26 positioned in the opening 38 and between the firstand second planes 46, 48). The portion of the blade 26 not positioned inthe cut zone 44 is substantially enclosed, or inaccessible, when thehousing 12 is in the closed position. The blade guard 20 includes a sidewall 134 extending about the perimeter of the band saw blade 26, and abottom wall 136 extending from the side wall 134 to cover the cuttingedge 114 of the band saw blade 26 and portions of the bottom of thedrive and driven wheels 62, 64. The bottom wall 136 includes first andsecond openings 138, 140 positioned centrally over portions of the driveand driven wheels 62, 64, respectively. The openings 138, 140 areapproximately centered about the drive axis 66 and the driven axis 70,respectively (FIG. 12). The openings 138, 140 are positioned proximateat least a portion of the drive and driven wheels 62, 64 respectively toallow chips and debris carried by the blade 26 an outlet from thehousing 12.

With reference to FIGS. 7, 9 and 12, the blade guard 20 includes chipvents 144 adjacent the blade 26 as the blade exits the cut zone 44. Inthe illustrated construction, the chip vents 144 are positioned on thefirst housing portion 40 proximate the drive wheel 62 and the shoe 116.The chip vents 144 provide an outlet for chips and debris from thehousing 12. With particular reference to FIGS. 7 and 9, wear plates 146are received on an inner surface of the blade guard 20 adjacent thecutting edge 114 of the blade 26 for preventing the blade 26 fromcutting through the blade guard 20. The wear plates 146 are preferablyformed of a metal, such as steel or aluminum, or another suitablematerial that is harder than the material of the blade guard 20. In theillustrated construction, the wear plates 146 are located on the secondhousing portion 42, or driven wheel side of the blade guard 20. In otherconstruction, the wear plates 146 may additionally or alternatively bepositioned on the first housing portion 40, or drive wheel side of theblade guard 20.

A pair of latches 142 couple the blade guard 20 to the deck 14 in theclosed position. The latches 142 are substantially mirror images of theeach other. The latches 142 each include a deck lip 148 (FIG. 13)generally extending from the deck 14 and disposed at outer ends of thelatches 142 with respect to the opening 38, a guard lip 150 extendingfrom the blade guard 20 and disposed at inner ends of the latches 142with respect to the opening 38 and a generally C-shaped latch member152. The latch members 152 are slidably coupled to the deck 14 such thatthey are slidable between a locked position (FIGS. 1-4, 6, 12) in whichthe deck 14 and blade guard 20 are substantially fixed relative to oneanother and an unlocked position (FIG. 7) in which the blade guard 20 isfree to pivot away from the deck 14 on the hinge 124. The latch members152 slide in a direction generally perpendicular to the drive wheel axis66.

With reference to FIG. 7, in the open position, the latch members 152are positioned away from the opening 38 such that the latch members 152engage, and are positioned about, the deck lips 148. With reference toFIG. 2, in the closed position, the guard lips 132 are positionedtowards the opening 38 such that the latch members 152 engage, and arepositioned about, the guard lips 150 to lock the blade guard 20 to thedeck 14. In the closed position, the guard lips 150 are generallyparallel and adjacent to the deck lips 148.

FIG. 6 illustrates a cross section of the latch 142 in which the latchmember 152 is in the locked position. The latch 142 includes a detentmechanism 154 that provides a threshold force below which the latchmember 152 will not slide between the locked and unlocked positions. Thedetent mechanism 154 includes first and second projections, ribs orbumps 156, 158, respectively, formed on a surface, such as the uppersurface 112, of the deck 14. A cantilevered spring arm 160 is formed onan inner surface of the latch member 152 facing the deck 14 and includesa projection 162 extending towards the deck 14, and specifically towardsthe bumps 156, 158. The projection 162 cooperates with the first andsecond bumps 156, 158 to provide the threshold force for sliding thesliding member between the locked and unlocked positions. The spring arm160 deflects under a force greater than the threshold force such thatthe latch member 152 slides past the first bump 156 and subsequently thesecond bump 158 to the unlocked position. If the force applied is lowerthan the threshold force, the projection 162 abuts the first or secondbump 156, 158 to inhibit the latch member 152 from sliding.

FIGS. 7 and 11 illustrate a tire brush 164 formed from bristles made ofa polymer, such as nylon. In other constructions, the bristles may bemade of other polymers, metals and other suitable materials. The tirebrush 164 is received in a bristle receptacle 166 extending from aninner surface of the blade guard 20 proximate the opening 138 for thedrive wheel 62. The tire brush 164 is positioned in contact with thedrive wheel tire 74 to clean chips and debris from the drive wheel tire74. The tire brush 164 is sandwiched within the receptacle 166 andsecured in place by a cap 168 fastened to the receptacle 166 by afastener 170, such as a screw. The screw 170 and cap 168 are readilyremovable when the blade guard 20 is open for easy replacement of thetire brush 164.

FIG. 13 illustrates an exploded view of the band saw 10. The band saw 10includes a reinforcement plate 172 formed of a metal and disposedbetween the deck 14 and the wheels 62, 64 for providing rigidity to thehousing structure 12 of the band saw 10. The reinforcement plate 172includes a drive portion 174 located proximate the drive wheel 62, adriven portion 176 located proximate the driven wheel 64 and a bridgeportion 178 extending between the drive and driven portions 174, 176.The drive wheel 62 is positioned adjacent a bottom surface of the driveportion 174 and the driven wheel 64 is positioned adjacent a bottomsurface of the driven portion 176. The drive portion 174 is secured tothe gear box 18 by fasteners such as screws (not shown). The gear box 18is, in turn, fastened to the deck 14. The driven portion 176 is fastenedto the deck 14 by fasteners, such as screws (not shown). The driveportion 174 includes an aperture 180 for receiving the drive wheel axle68 therethrough, and the driven portion 176 includes a slot 182 forreceiving the driven wheel axle 72 therethrough and accommodatingmovement of the driven wheel axle 72 as a result of the tensioningmechanism 78.

The tensioning mechanism 78 is trapped in a space between the drivenportion 176 of the reinforcement plate 172 and an inner surface of thedeck 14. With reference to FIGS. 14 and 15, a distal end of the springguide 88 abuts the reinforcement plate 172 to inhibit the tensioningmechanism 78 from tilting in a first direction, and the tilting block100 bears against a metal insert 184, which is coupled to the deck 14(FIG. 13) to inhibit the tensioning mechanism 78 from tilting in asecond direction opposite the first direction. Thus, the tensioningmechanism 78 is trapped between the reinforcement plate 172 and theguard 14.

In operation of the band saw 10, an operator grips the grip portion 34of the handle 30 with one hand and actuates the trigger 32 with the samehand. Actuation of the trigger 32 causes the motor 16 and drive assembly24 to rotate the drive wheel 62 about the drive wheel axis 66, causingmotion of the band saw blade 26 for cutting the workpiece 28 in the cutzone 44. Because the grip portion 34 is positioned at least partiallybetween the first and second planes 46, 48 bounding the cut zone 44, oropening 38, the operator's hand is also positioned between the first andsecond planes 46, 48 during the cutting operation. The bridge 104 limitsmovement of the workpiece 28 after the cutting operation is complete.Furthermore, the guard 20 protects the cutting edge 114 of the blade 28when the cutting edge 114 is not positioned in the cut zone 44.

Thus, the invention provides, among other things, a compact band sawhaving a workpiece guard and a blade guard. Various features andadvantages of the invention are set forth in the following claims.

What is claimed is:
 1. A method of manufacturing a band saw comprising:providing a deck; coupling first and second wheels to the deck forreceiving a continuous blade thereabout; coupling a motor to the deckfor driving at least one of the first or second wheels; providing ahandle for a user to hold the band saw; providing a blade guard having afirst portion adjacent the first wheel and a second portion adjacent thesecond wheel; fixing the first and second portions to each other; andhingedly coupling the first and second portions to the deck forsimultaneous movement with respect to the deck.
 2. The method of claim1, further comprising providing a first latch coupling the first portionto the deck and a second latch coupling the second portion to the deckfor simultaneous latching of the first and second portions with respectto the deck.
 3. The method of claim 2, wherein providing the first andsecond latches includes providing cantilevered spring arms.
 4. Themethod of claim 2, wherein providing the first and second latchesincludes providing a member that overlaps a projection on the bladeguard.
 5. The method of claim 1, further comprising providing a latchcoupling at least one of the first or second portions to the deck. 6.The method of claim 1, wherein hingedly coupling includes providingsubstantially coaxial barrel sections between the first portion and thedeck and between the second portion and the deck, respectively.
 7. Themethod of claim 1, further comprising: providing a substantiallystraight edge extending from the first portion to the second portion;and forming the substantially straight edge to extend across at least aportion of the first portion, across substantially an entire length ofan intermediate portion between the first and second portions, andacross at least a portion of the second portion; wherein hingedlycoupling includes coupling the blade guard to the deck at thesubstantially straight edge such that the first, second, andintermediate portions are hinged along a single axis.
 8. The method ofclaim 7, further comprising forming a generally semi-circular edge oneach of the first and second portions, wherein the substantiallystraight edge extends between the generally semi-circular edges.
 9. Ahand-held band saw for cutting a workpiece, the hand-held band sawcomprising: a deck; first and second wheels coupled to the deck forreceiving a continuous blade thereabout; a motor coupled to the deck fordriving at least one of the first or second wheels; a handle providing agrip for a user to hold the band saw; a blade guard having a firstportion adjacent the first wheel, a second portion adjacent the secondwheel, and a third portion adjoining the first and second portions; anda joint coupling the first, second, and third portions to the deck forsimultaneous movement of the first, second, and third portions withrespect to the deck.
 10. The hand-held band saw of claim 9, furthercomprising a first latch coupling the first portion to the deck and asecond latch coupling the second portion to the deck for simultaneouslatching of the first and second portions with respect to the deck. 11.The hand-held band saw of claim 10, wherein the first and second latchesinclude cantilevered spring arms.
 12. The hand-held band saw of claim10, wherein the first and second latches include a member that overlapsa projection on the blade guard.
 13. The hand-held band saw of claim 9,further comprising a latch coupling at least one of the first or secondportions to the deck.
 14. The hand-held band saw of claim 9, wherein thejoint further comprises substantially coaxial barrel sections betweenthe first portion and the deck and between the second portion and thedeck, respectively.
 15. The hand-held band saw of claim 9, furthercomprising: a substantially straight edge extending from the firstportion to the second portion; wherein the substantially straight edgeextends across at least a portion of the first portion, acrosssubstantially an entire length of an intermediate portion between thefirst and second portions, and across at least a portion of the secondportion; wherein the blade guard is coupled to the deck at thesubstantially straight edge such that the first, second, andintermediate portions are hinged along a single axis.
 16. The hand-heldband saw of claim 15, further comprising a generally semi-circular edgeon each of the first and second portions, wherein the substantiallystraight edge extends between the generally semi-circular edges.
 17. Ahand-held band saw for cutting a workpiece, the hand-held band sawcomprising: a deck defining a front and a rear, the deck having anopening in the front defining a cut zone and a first deck portiongenerally located on a first side of the opening and a second deckportion generally located on a second side of the opening; a first wheelsupported by the first deck portion; a second wheel supported by thesecond deck portion, the first and second wheels for supporting a blade;a motor operably coupled to the first wheel; a handle providing a gripfor a user to hold the band saw; a blade guard configured to provide abarrier between the blade and an exterior of the band saw; and a jointbetween the blade guard and the deck such that the blade guard ismovable with respect to the deck; wherein the blade guard includes afirst portion adjacent the first wheel, a second portion adjacent thesecond wheel, and a third portion adjoining the first and secondportions such that the first, second, and third portions move as onepiece with respect to the deck.
 18. The hand-held band saw of claim 17,wherein the joint is disposed at the rear.
 19. The hand-held band saw ofclaim 17, further comprising: a substantially straight edge extendingfrom the first portion to the second portion; wherein the substantiallystraight edge extends across at least a portion of the first portion,across substantially an entire length of the third portion, and acrossat least a portion of the second portion; wherein the joint is coupledto the substantially straight edge such that the first, second, andthird portions are hinged along a single axis.
 20. The hand-held bandsaw of claim 19, wherein the first and second portions each include agenerally semi-circular edge, wherein the substantially straight edgeextends between the generally semi-circular edges.